INJECTION PUMP SPECIFICATION ©

FULL LOAD RPM: 1500 CUSTOMER PART #: 3502 2029H MODEL NO.: DB4427-5019
GOV. REGULATION: 3-5 % CUSTOMER'S NAME: VM SUPERSEDES:
ENGINE: SUN 4 T EDITION NO.: 20
APPLICATION: GENERATOR DATED: 05-27-04

NOTE: ALL SPEEDS ARE IN ENGINE RPM UNLESS OTHERWISE NOTED.

USE LATEST REVISION FOR ALL REFERENCED DOCUMENTS.
TEST STAND: PUMP SETTINGS: FOLLOWING PUMP SERVICE
1. CALIBRATING HIGH PRESSURE PIPES...SAE J1418/ISO 4093: 1. ROLLER-TO-ROLLER DIMENSION: 1.9675" ± .0015"
.063" (1.6 mm) I.D. X 25" (635 mm) LONG. (49.97 ± 0.04 mm)
2. CALIBRATING INJECTORS... S.A.E. J968/ISO 7440: MAXIMUM ECCENTRICITY: .004" (0.10 mm) T.I.R.
0.5 mm ORIFICE PLATE NOP: 3000 PSI (207 bar) LONG. 2. GOVERNOR LINKAGE GAP: .125"-.145" (3.2-3.7 mm)
3. CALIBRATING FLUID...SAE J967/ISO 4113 (REF. S.B. 201): (USE KIT #23093 S.B. 95)
a. TEMPERATURE AT INLET: 110°-115°F (43°-46°C) 3. 1000 RPM (WOT): OPERATE PUMP FOR 10 MINUTES TO BRING TO
b. SUPPLY PRESSURE (S.B. 334): 5.0 ± 0.5 PSI OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM.
(34-36 kPa) AT PUMP INLET. 4. 400 RPM (WOT):
4. CAM MOVEMENT READOUT DEVICE: #23745. a. CHECK SHUT-OFF: 4 mm³/STROKE, MAX.
b. CHECK FOR MINIMUM TRANSFER PUMP LIFT OF 18" HG.
PUMP INSTALLATION: IT-032 (60 kPa).
ROTATION-C-* LEVER ANGLES (REF) 5. 1500 RPM (WOT):
NAME PLATE-L-SIDE** THOT MIN. (∠B) N/A a. SET TRANSFER PUMP PRESSURE FOR 76-79 PSI,
#1 CYL. -4-O'CLOCK** THOT MAX. (∠C) N/A (526-546 kPa)(SUPPLY SET PER TEST STAND NOTE 3B).
THROTTLE-L-SIDE** S.O. (∠ E) N/A b. ADJUST RETURN OIL TO 225-475 CC/MIN. RECHECK TRANSFER
TIMING MARK N/A S.O. (∠ F) N/A PUMP PRESSURE.
E.S.O. (12V E.T.R.) c. CHECK HOUSING PRESSURE FOR 4-10.5 PSI, (28-72 kPa).
d. BACK-OUT TRIMMER SCREW TO MEASURE 0.5O" (1.27 mm)
* VIEWED FROM DRIVE END ** VIEWED FROM TRANSFER PUMP END FROM FACE OF ADVANCE END PLUG. USING THE SPRING SIDE
ADVANCE PLUG, ADJUST FOR TOTAL ADVANCE TRAVEL OF 6°.
PUMP OPERATING SPEED...HALF...ENGINE SPEED e. TURN SPEED DROOP ADJUSTING CAP IN 5 FULL TURNS,
AIR TIMED TO HOUSING (S.B. 177)(SEE SPECIAL NOTES) CLOCKWISE.
MARK WEIGHT CAGE TO CAM 6. 1150 RPM (WOT): SET ADVANCE TRIMMER SCREW FOR 4.75°.
7. 1500 RPM (WOT): SET ROLLER-TO-ROLLER FUEL DELIVERY:
PUMP CALIBRATION CHECKS: AS RECEIVED FOR SERVICE 93-94 mm³/STROKE.
(REF. SL-222)(REF. S.B. 97R FOR SPEED DROOP) 8. 1625 RPM (WOT): ADJUST HIGH IDLE SCREW TO OBTAIN 4 MAX
1. 1000 RPM (WOT): OPERATE PUMP FOR 10 MIN. TO BRING TO mm³/STROKE.
OPERATING TEMPERATURE AND CLEAR AIR FROM SYSTEM. 9. CHECK POINTS:
2. TURN SPEED DROOP TO MINIMUM POSITION (C'C DIRECTION).
3. 1625 RPM (WOT): RESET HIGH IDLE SCREW TO OBTAIN 4 MAX THROTTLE T.P.
mm³/STROKE. RPM POSITION mm³/STROKE ADVANCE PRESSURE
4. CHECK POINTS: (SEQUENCE MUST BE FOLLOWED AS LISTED) a. 150 WOT 48 MIN. --- 10 MIN.**
b. 400 WOT* 4 MAX. --- ---
THROTTLE c. 1150 WOT --- 4.0°-5.5° ---
RPM POSITION mm³/STROKE ADVANCE d. 1200 L.I.** 12-16 --- ---
a. 150 WOT 45 MIN. --- e. 1500 WOT 93-94 5.75°-6.25° 76-79***
b. 400 WOT* 4 MAX. --- f. 1500 WOT* 4 MAX. --- ---
c. 1150 WOT --- 3.75°-5.75° g. 1625 WOT 4 MAX. --- ---
d. 1200 L.I.** 12-16 ---
e. 1500 WOT 92-95 5.75-6.25 * E.S.O. DE-ENERGIZED ** (69 kPa) *** (526-546 kPa)
f. 1500 WOT* 4 MAX. ---
g. 1625 WOT 4 MAX. --- 10. SPECIAL NOTES:
a. TORQUE ALL FASTENERS PER S.B. 106.
* E.S.O. DE-ENERGIZED b. ASSEMBLE THROTTLE LEVER SPACER AND ARM IN B4-L
** RESET USING LOW IDLE SCREW, IF NECESSARY POSITION PER S.B. 164.
c. ADJUST SPEED DROOP PER S.B. 97R.
d. SEAL FASTENERS PER S.B. 134R.
AIR TIME PUMP USING HARTRIDGE BASIC AIR TIMING TOOL
7244-27 WITH ADPATER P/N 29711 CONNECT AIR SUPPLY
WITH 60-100 PSI (4.1-6.9 BAR) TO #1 CYLINDER OUTLET.
SET TOOL TO 110° AND INSTALL TO DRIVE SHAFT.
SLOWLY ROTATE TOOL CLOCKWISE UNTIL ROLLERS
STRIKE CAM RING AND TOOL STOPS, SCRIBE LINE ON
HOUSING FLANGE. REPEAT PROCEDURE TO ENSURE
ACCURACY. IF INTERFERENCE BETWEEN STRAIGHT EDGE
AND HOUSING FLANGE OCCURS, PLACE WASHER (i.e.
13521) BETWEEN STRAIGHT EDGE AND TOOL.
11. PUMP TO BE TESTED PER S.B. 478.
12. PUMP MAY BE CONVERTED TO 24V. E.T.R. WITH PART NUMBER
26387 SOLENOID FRAME ASSY WITHOUT CHANGE IN THE PUMP
MODEL. THE GOVERNOR COVER AND PUMP NAMEPLATE MUST BE
STAMPED 24V.

© STANADYNE Corporation, all rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any
form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from the publisher.
DB4427-5019 EDITION 20 DATED 05/27/2004 PAGE 2 OF 4
DESCRIPTION QTY P/N HOUSING & DRIVE GROUP P/N QTY DESCRIPTION
(63696)
DRIVESHAFT 1 30386
WASHER, DRIVESHAFT 1 32787 36534 1 SEAL, DRIVE SHAFT
NUT, HEX 1 26346
30804 1 SEAL, TEFLON LIP
KEY, WOODRUFF 1 30387
21660 1 SCREW ASSY, VENT
OR 21661-21665
HOUSING ASSY, PUMP 1 34404
SEAL, RECT SECTION 1 19840
12259 1 SCREW, PAN HEAD
10464 1 WASHER, SEALING

11331 2 SCREW, HEX HEAD

28749 1 BEARING, THRUST
SCREW, RIVET 2 24419 26468 1 WASHER, THRUST

NAMEPLATE 1 10394
26469 1 RING, RETAINING
GASKET, TIMING WINDOW CVR 1 27603
28381 1 WASHER, DRSFT SPRING
COVER, TIMING WINDOW 1 23107
SCREW, HEX HEAD 2 21194

NOTES:

DESCRIPTION QTY P/N HEAD & ROTOR GROUP P/N QTY DESCRIPTION
(60386)
SCREW, LEAF SPR ADJ 2 15619 32227 1 H&R ASSY, HYD 4 CYL
11046 2 PLUNGER, ROTOR
SHOE, CAM ROLLER 4 20123 USE 11047-11050 (STD)
OR 20121 (+.005) OR OR 11052-11055 (O/S)
20124 (-.005) AS REQ'D
REF S.B. 332 15709 2 PLUNGER, ROTOR
USE 15710-15713 (STD)
OR 15960-15963 (O/S)
AS IND. ON ROTOR S.B.60R
11438 1 SCREW, SET
SPRING, LEAF 2 29932 12216 1 SCREW, HEAD PLUG
ROLLER, CAM 4 11141
20727 4 CONNECTOR, FUEL LINE
RING, CAM 1 21687
27601 1 SEAL, O-RING
29710 1 SCREW, SKT HEAD CAP
29384 1 PLATE, SINTERED LOCK
21215 1 VALVE, DELIVERY
SEAL, O-RING 1 27245 OR 21216 (O/S) AS REQ'D
REF S.B. 143B

SPRING, DLVY VALVE 1 20129 20127 1 SCREW, RETAINING

STOP, DELIVERY VALVE 1 20128

NOTES:

DESCRIPTION QTY P/N TRANSFER PUMP GROUP P/N QTY DESCRIPTION

(60054)
20530 2 RETAINER, ROTOR
SEAL, TRANSFER PUMP 1 27608
21232 1 LINER, TRANSFER PUMP
20511 4 BLADE, TRANSFER PUMP
OR 20512 REF. S.B. 304
20528 1 RING, ROTOR RETAINER

28987 1 REGULATOR ASSY, TP

SPRING, TP BLADE 2 15699
ROLL PIN 1 19837
SEAL, TP RGLTR SLEEVE 1 19844

28135 1 SPRING, REGULATING

PISTON, REGULATING 1 19895

PLUG ASSY, END PL ADJ 1 15228

FILTER, INLET 1 28986 33128 1 CAP, TP END

NOTES:

INDENTED ITEMS INCLUDED

DB4427-5019 EDITION 20 DATED 05/27/2004 PAGE 3 OF 4
DESCRIPTION QTY P/N GOVERNOR GROUP P/N QTY DESCRIPTION
(63372)
SPRING, SPEED DROOP 1 13562 20240 1 ROD ASSY-CONTROL
YELLOW
ARM ASSY, GOVERNOR 1 20956 13554 1 PIN, CONTROL SPRING

SHAFT, GOVERNOR ARM 1 12214 27606 1 WASHER, SEALING

SEAL, O-RING 2 31332 12966 1 SEAL, O-RING

NUT, PIVOT SFT RTNR 2 12288 36556 1 CAP, ADJUSTING

SPRING, DAMPER 1 20475 20355 1 CAP, DROOP CTRL LOCK

PISTON ASSY, DAMPER 1 16572

27599 1 GUIDE, CONTROL ROD
16568 1 BARREL ASSY, DAMPER
21895 1 ARM ASSY, MTR VALVE
SLEEVE, GOVERNOR THRUST 1 36498 11563 1 VALVE, METERING
* SEE NOTE
26427 1 SHIM, MTR VALVE SPRG
WASHER, THRUST 1 19860 20359 1 SPRING, MTR VALVE

WEIGHT, GOVERNOR 6 19858 29136 3 CLIP, RETAINING

REF. S.B. 370
RETAINER ASSY, GOV WT 1 19893 19894 3 RETAINER, CUSHION
19873 6 CUSHION, GOV WT RNTR
NOTES: * O.S. METERING VALVE AND ARM ASSY 22249 REFERENCE S.B.336

DESCRIPTION QTY P/N LINKAGE GROUP P/N QTY DESCRIPTION

(63721)
SEAL, O-RING 2 17438
WASHER, SPACER 2 14408
SHAFT ASSY, THROTTLE 1 16251 16279 1 SHAFT, SHUTOFF

SCREW, HEX HEAD 1 12972

12253 1 CLIP, SHAFT RETAINER
NUT, HEX 1 12174
12221 1 LEVER, THROTTLE FORK
15306 1 SPACER, GOV SPRING
12167 1 SCREW, HEX HEAD
SPACER, THROT LVR ADJ 1 16135
12174 1 NUT, HEX
SCREW, SOCKET CAP 1 12051
ARM, ADJUSTING SPACER 1 16136 18021 1 HOOK ASSY, GOV LKGE
12360 1 SCREW, HEX HEAD
LEVER ASSY, THROTTLE 1 15026 12362 1 LOCK WASHER, SHPRF
SPRING, THROT LEVER 1 13003 18020 1 HOOK, GOV LINKAGE

12358 1 LINK ASSY, ADJUSTING

11919 1 SPRING, GOVERNOR LINK
SCREW, SKT HEAD CAP 1 15668
RNTR, THROT LVR SPR 1 13010

NOTES:

DESCRIPTION QTY P/N AUTOMATIC ADVANCE GROUP P/N QTY DESCRIPTION

(60381)

PISTON, SERVO ADVANCE 1 21149 21161 1 PLUG, POWER SIDE END

VALVE, PILOT 1 22156 26126 1 SEAL, O-RING

19834 1 SCREW, REED VALVE
SEAT, PILOT VALVE SPR 1 21731
21146 1 VALVE, CHECK

SPRING, SERVO ADVANCE 1 21152

PIN, ADVANCE CAM 1 21147 22293 1 SEAL, O-RING

PLUG, SPRING SIDE END 1 21150 22080 1 LOCKNUT, ADV END PLUG

SCREW, ADV TRIMMER 1 21729

SEAL, O-RING 1 21955 27602 2 SEAL, O-RING
LOCKNUT, TRIMMER SCR 1 22081
22237 1 SCREW ASSY, HD LCTING
0.015
SEAL, O-RING 1 27610

PLUG, HEX SOCKET 1 23056

NOTES:

INDENTED ITEMS INCLUDED

DB4427-5019 EDITION 20 DATED 05/27/2004 PAGE 4 OF 4
DESCRIPTION QTY P/N COVER GROUP P/N QTY DESCRIPTION
(61101)
14760 2 NUT, HEX LOCK

28388 1 TERMINAL, ESO

12519 2 NUT, HEX

SCREW, BUTTON HD CAP 3 22351
12500 2 WASHER, FIBER
26564 1 RGLTR ASSY, HSG PRESS
STRAP, TERM GROUNDING 1 20951
WASHER, INTL TOOTH 2 12049 30789 1 CAP, COVER SCREW

WASHER, INTL TOOTH 1 18493

30788 1 CUP, COVER SCREW
WASHER, PLAIN 2 18501
27607 1 SEAL, O-RING

22567 1 COVER, GOV CONTROL

SEAL, RECTANGULAR SECTION 1 27244

26214 1 SOLENOID, 12V ETR

2-23190 TUBE, INSULATE

NOTES: INSTALL GROUNDING STRAP ON LEFT SIDE VIEWING TRANSFER PUMP REFERENCE S.B. 108

FOR SERVICE USE ONLY FOR ENGINEERING USE ONLY

APPLICABLE SERVICE ASSEMBLIES DATE CHANGE NO. EDITION
THROTTLE SHAFT BUSHING REPLACEMENT 17776 10/23/1991 20439 1
ESO MOUNTING AND GROUNDING KIT 26431 10/23/1991 21110 1
OVERSIZE ADVANCE PISTON (.008) 27968 08/31/1992 21803 2
DRIVE SHAFT SUPPORT TUBE 30586 10/06/1992 21908 3
GASKET KIT 33702 11/16/1992 22098M 4
01/04/1993 21485 5
01/04/1993 22194 5
02/08/1993 22298 6
03/02/1993 22341M 7
04/02/1993 22416 8
01/19/1994 22987 9
04/24/1995 23825 10
01/03/1996 24058 11
01/19/1996 24058 12
05/03/1996 24058 13
11/07/1998 25814 14
03/25/2002 27718 15
07/31/2003 27563 16
10/23/2003 26277 17
01/13/2004 28511 18
02/26/2004 28594 19
05/27/2004 28750 20

INDENTED ITEMS INCLUDED